01/04/2024 13:56:52

Brake Lines - LH Sill (Structural Pack) (Remove and Replace)

Correction code 33035112 1.86 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so.NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

2023-12-08: Updated brake stiffness routine.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

Remove the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
Remove butyl patches covering LH rocker access holes

Note
2x butyl patches, Clean excess butyl from area
Install lift pad adapters onto LH rocker

Note
2x lift pad adapters
Remove the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
Remove butyl patches covering RH rocker access holes

Note
2x butyl patches, Clean excess butyl from area
Install lift pad adapters onto RH rocker

Note
2x lift pad adapters
Raise and support vehicle

Note
Verify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
Open LH front door
Lower LH front window
Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Remove bolt securing frunk to washer fluid reservoir neck

Note
1x bolt, 10mm, 5 Nm
Release washer tank neck from washer tank and set aside

Note
1x O-ring, No need to remove hose from neck
Remove HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot rearward edge up and past brake reservoir, then lift up to clear frunk assembly
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect LV battery connector and First Responder Loop

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
Remove all four wheels. See Wheel Assembly (Remove and Install).
Release LH front wheel liner from HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
Remove the LH front fender garnish. See Garnish - Fender - Front - LH (Remove and Replace).
Remove the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Structural Pack) (Remove and Replace).
Remove the LH rear wheel arch liner. See Wheel Arch Liner - Rear - LH (Structural Pack) (Remove and Replace).
Release clipping points securing compressor HV harness to front of vehicle body

Note
5x clips, Take note of original routing
Release clipping points securing compressor HV harness to side of vehicle body

Note
8x clips, Release all clipping points
Release side sill brake pipe assembly from LH front junction block

Note
2x nuts, 12mm, 16 Nm, Front brake pipe B and C bundle does not detach from junction block
Release rear brake lines from LH rear junction block

Note
2x nuts, 12mm, 16 Nm, Side sill brake pipe assembly does not detach from junction block
Remove bolt securing LH rear junction block to body

Note
1x bolt, 10mm, 6 Nm
Release side sill brake pipe assembly from clips

Note
7x clips, Do not bend pipe
Remove side sill brake pipe assembly

Note
1x stud, Release LH rear junction block from body stud then remove assembly from front wheel well

Install

Position side sill brake pipe assembly

Note
1x stud, Position assembly onto front wheel well then secure LH rear junction block onto body stud
Secure side sill brake pipe assembly onto clips

Note
7x clips, Do not bend pipe, Start with front clip and align pipes with LH front junction block
Install bolt securing LH rear junction block to body

Note
1x bolt, 10mm, 6 Nm
Secure rear brake lines onto LH rear junction block

Note
2x nuts, 12mm, 16 Nm, Side sill brake pipe assembly does not detach from junction block
Secure side sill brake pipe assembly onto LH front junction block

Note
2x nuts, 12mm, 16 Nm, Front brake pipe B and C bundle does not detach from junction block
Install clipping points securing compressor HV harness to side of vehicle body

Note
8x clips, Fully secure all clips and route harness as needed
Install clipping points securing compressor HV harness to front of vehicle body

Note
5x clips, Return to original routing, Verify fully secured
Lower vehicle for access to underhood area

Note
Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Connect first responder loop and LV battery

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Fill brake bleeder reservoir to full level
Clean area around brake fluid reservoir and remove brake reservoir cap
Top off brake fluid reservoir

Note
Top off brake fluid as needed
Install pressure bleeder adapter onto reservoir
Set brake bleed reservoir pressure to 30 psi

Note
Connect power supply to bleeder and turn on the power, Set pressure to 30 psi, Attach brake bleed reservoir to brake bleed adapter
Connect to vehicle using Toolbox 3.0

Note
Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle. https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)
Select Actions/Autodiag and search for "bleed"
Remove bleeding valve covers and install the fluid catching bottle to LH front brake caliper outer bleeding valve before starting the ESP

Note
2x covers
Open LH front brake caliper outer bleeding valve then click the play button next to "PROC_ESP_FRONT-L-REAR-R_BRAKE_BLEED" and select Run to start the ESP, then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Repeat the above step till clear fluid and no air bubbles come out of the LH front brake caliper bleeding valve

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove the fluid catching bottle, Torque LH front brake caliper bleeding valves then install covers

Note
2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove bleeding valve covers and install the fluid catching bottle to RH front brake caliper outer bleeding valve before starting the ESP

Note
2x covers
Open RH front brake caliper outer bleeding valve then Click the play button next to "PROC_ESP_FRONT-R-REAR-L_BRAKE_BLEED" and select Run to start the ESP, then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Repeat the above step till clear fluid and no air bubbles come out of the RH front brake caliper bleeding valves

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove the fluid catching bottle, Torque RH front brake caliper bleeding valves and install covers

Note
2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove bleeding valve cover and install the fluid catching bottle to RH rear brake caliper bleeding valve before starting the ESP

Note
1x cover
Open RH rear brake caliper bleeding valve then Click the play button next to "PROC_ESP_FRONT-L-REAR-R_BRAKE_BLEED" and select Run to start the ESP, then close the bleeding valve once the pump stop running

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Repeat the above step till clear fluid and no air bubbles come out of the RH rear brake caliper bleeding valve

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove the fluid catching bottle, Torque RH rear brake caliper bleeding valve and install cover

Note
1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove bleeding valve cover and install the fluid catching bottle to LH rear brake caliper bleeding valve before starting the ESP

Note
1x cover
Open LH rear brake caliper bleeding valve then Click the play button next to "PROC_ESP_FRONT-R-REAR-L_BRAKE_BLEED" and select Run to start the ESP, then close the bleeding valve once the pump stop running

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Repeat the above step untill clear fluid and no air bubbles come out of the LH rear brake caliper bleeding valve

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove the fluid catching bottle, Torque LH rear brake caliper bleeding valve and install cover

Note
1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Power off brake bleed reservoir and detach brake bleed reservoir from brake bleed adapter
Remove pressure bleeder adapter from reservoir
Check fluid level

Note
Top off if necessary
Install brake reservoir cap
Pump the brake pedal a few times to ensure the brake pedal feels normal
Using Toolbox 3:
1. Select the Actions tab and search for "Stiffness".
2. Select the ODIN routine IBST Stiffness Test - Service - BURNISHED/UNBURNISHEDTEST_BRAKE_X_STIFFNESS-TEST-SERVICEGen3/tasks/TEST_BRAKE_X_STIFFNESS-TEST-SERVICEChassisChassis / Brakes - Brake Stiffness TestService Mode Service Plus Factory Mode Developer , and then click the link of the routine.
3. If brake pads or rotors have been replaced, select UNBURNISHED under "Action_Type". In all other cases, select BURNISHED.
4. Click RUN, and allow the routine to complete.
  
  Note
  Do not press the brake pedal during the test.
Remove ethernet cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Raise vehicle partially and lower lift onto locks

Note
Set vehicle to a comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Install the LH rear wheel arch liner. See Wheel Arch Liner - Rear - LH (Structural Pack) (Remove and Replace).
Install the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Structural Pack) (Remove and Replace).
Install all four wheels. See Wheel Assembly (Remove and Install).
Install HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, then carefully move rear edge past brake reservoir and into position
Install washer tank neck to washer tank

Note
1x O-ring, Ensure washer hose is properly routed after installation
Secure frunk to washer fluid reservoir neck

Note
1x bolt, 10mm, 5 Nm
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Remove vehicle from lift

Note
Lower rack arms fully and remove from under vehicle
Raise LH front window
Close LH front door
Remove lift pad adapters from LH rocker

Note
2x lift pad adapters
Install butyl patches onto LH rocker access holes

Note
2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
Remove the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
Remove lift pad adapters from RH rocker

Note
2x lift pad adapters
Install butyl patches onto RH rocker access holes

Note
2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
Install the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).